Fender-Cowl repair. Advice needed!, Anyone have detailed pics of the rust channel? Options

[Gudhjem]

I've had bubbling showing through on both sides of the fender-cowl seem, which was welded together by the PO. So I knew I had some problems, and finally started digging in. Here are a few pics of what I found:




I know. (IMG:style_emoticons/default/barf.gif)

It's not quite as bad as those pics make it look (I hope) since the rust seems to be localized to the area right at the former cowl seems, which look like they were welded shut without treating existing rust underneath. Other than right in the corners, the hood channels, etc. look pretty good.

I've been working out how to go about rebuilding this area all week. I'd like to reconstruct the channel, not reweld it closed, and I'd like to do it right, not just cover the problem. Several pieces come together here, and it's not clear to me how it's even possible to weld all of these together, even with the fender removed. How, for example, does one fully-weld the drain channel so that it doesn't invite water seeping in the seams that are left?

I've scoured the sites for rebuild threads that include this area, and found several good ones with helpful pics of the area (Michelko's Digging into Hell, Bringing out the Dead, among others). I haven't been able to figure out exactly how all these restoration heroes went about this fix.

I'm wondering if anyone has pics of this area that clearly show the construction. I think I have it deciphered, but not 100% sure since mine was already repaired and welded shut.

Maybe someone can share some wisdom on how to go about the reconstruction? Specifically what to weld to what, etc. (IMG:style_emoticons/default/welder.gif)

--Steve

[charliew]

I agree in that if the area has rusted I would take enough of the top off and fix the underlying area, and add a cross brace to the inside of the cowl down to the inner part of the fender to support the door hinge post area, even if it is just round rod, treat the surrounding area, paint it with epoxy primer, then weld the entire area up with a one piece cover. My idea is to stop the flex. Also I would add a shield in the front up to the underside of the fender to stop water and dirt from getting up in the area. Just my idea and it may be bogus. It does seem though that the factory went to a lot of trouble to have a seam there so they must have thought it needed to be flexible.